Construction of high-rise building with large modular units

Abstract

A method for constructing modular high-rise buildings is described. Precast modules forming a portion of a level of the building are formed at ground level, and are lifted in position on the level being assembled. Most of the finishing and testing work for the precast modules is carried out at ground level, resulting in a safer and less expensive construction. Once in place on the building's level, the precast modules are secured with concrete pours and other strengthening devices.

What is claimed is:  
     
         1 . A method of constructing a high-rise building comprising: 
 forming at ground level precast modules defining portions of a level of the building;    lifting the precast modules in position on the level of the building;    pouring a concrete overlay diaphragm on a floor of the level, such that the precast modules are held together in position; and    pouring concrete in spaces between vertical walls of the precast modules.    
     
     
         2 . The method according to  claim 1 , further comprising repeating the forming, lifting and pouring steps for a selected number of levels of the building.  
     
     
         3 . The method according to  claim 2 , further comprising constructing a core section of the building, said core section being connected to the level by shear walls.  
     
     
         4 . The method according to  claim 3 , further comprising assembling a tower gantry crane in the core section to lift the precast modules.  
     
     
         5 . The method according to  claim 1 , further comprising the preliminary step of building a foundation and a ground level of the building, said ground level having a roof portion adapted as the floor of a second level.  
     
     
         6 . The method according to  claim 1 , further comprising forming vertical stiffening columns at selected points of the precast modules, for connection to additional vertical stiffening columns formed in corresponding additional precast modules disposed on adjacent levels of the building.  
     
     
         7 . The method according to  claim 6 , further comprising threading steel dowels between the vertical stiffening columns and the additional vertical stiffening columns.  
     
     
         8 . The method according to  claim 1 , further comprising placing post-tensioning steel tendons vertically connecting outer corners of the precast modules to additional precast modules disposed on adjacent levels of the building.  
     
     
         9 . The method according to  claim 3 , further comprising placing post-tensioning steel tendons horizontally connecting outermost precast modules to the core section of the building.  
     
     
         10 . The method according to  claim 1 , further comprising assembling adjacent to the building precision forms used to make the precast modules at ground level, casting concrete in the precision forms, and removing after curing the precast modules from the precision forms.  
     
     
         11 . The method according to  claim 10 , further comprising, prior to casting concrete, disposing in the precision forms at least one of gunwale blocks, waffle panels, stud strips, door frames, window frames, and reinforcing elements.  
     
     
         12 . The method according to  claim 10 , further comprising disposing electrical wiring and plumbing connections in the precision forms prior to casting concrete.  
     
     
         13 . The method according to  claim 10 , further comprising securing at least one cross piece to the precast modules to increase torsional strength of the precast modules.  
     
     
         14 . The method according to  claim 10 , further comprising finishing and inspecting the precast modules after curing the concrete.  
     
     
         15 . The method according to  claim 10 , further comprising completing and testing windows of the precast modules after curing the concrete.  
     
     
         16 . The method according to  claim 3 , further comprising constructing additional core levels of the core section such that each core level is substantially completed before a corresponding level of the precast modules is started.  
     
     
         17 . The method according to  claim 16 , further comprising raising a self climbing tower gantry crane to the additional core levels.  
     
     
         18 . The method according to  claim 1 , further comprising building a top level of the building above the level formed of precast modules.  
     
     
         19 . The method according to  claim 1 , wherein the pouring concrete in spaces step comprises forcing concrete in the spaces left between the vertical walls when adjacent precast modules are lifted in position.  
     
     
         20 . The method according to  claim 1 , further comprising: 
 providing passages to allow concrete to flow across vertical walls of the precast modules; and    pouring the concrete overlay diaphragm such that concrete freely flows through the passages into all the precast modules.    
     
     
         21 . The method according to  claim 20 , further comprising disposing a reinforcement of at least one of steel rebar, wire mesh and wire fabric adjacent the floor prior to pouring the concrete overlay diaphragm.  
     
     
         22 . The method according to  claim 20 , further comprising providing interference connections between the concrete overlay diaphragm and the vertical walls of the precast modules.  
     
     
         23 . The method according to  claim 1 , further comprising setting up laser survey points to control positioning of the precast modules.  
     
     
         24 . The method according to  claim 2 , further comprising shoring a ceiling portion of the precast modules before pouring the concrete overlay diaphragm in a subsequent higher level of the building.  
     
     
         25 . The method according to  claim 3 , further comprising repeating the forming, lifting and pouring steps to construct a selected number of wings of the building.  
     
     
         26 . A method of construction for a modular level of a high-rise building, the level having a floor, comprising: 
 placing a precast module on the floor, such that the precast module defines a portion of the level of the building;    placing additional precast modules on the floor to define additional portions of the level, leaving spaces between adjoining vertical walls of the precast module and of additional modules that are mutually adjacent;    pouring a concrete overlay diaphragm on the floor, such that the concrete flows through passages in the vertical walls of the module and additional modules; and    pouring concrete in the spaces between adjoining vertical walls.    
     
     
         27 . The method according to  claim 26 , further comprising attaching post-tensioning tendons between one of the precast modules and additional precast modules and a core portion of the building.  
     
     
         28 . The method according to  claim 26 , further comprising disposing metal reinforcements adjacent the floor prior to pouring the concrete overlay diaphragm.  
     
     
         29 . The method according to  claim 26 , further comprising vertically connecting corners of the precast module and additional precast modules to corresponding corners of modules forming adjacent levels.  
     
     
         30 . The method according to  claim 26 , further comprising forming interference fittings between the vertical walls and the concrete overlay diaphragm.  
     
     
         31 . The method according to  claim 26 , further comprising defining laser survey points to accurately place the precast module and additional precast modules.  
     
     
         32 . The method according to  claim 29 , further comprising forming vertical stiffening columns at selected corners of the precast module and additional precast modules, and disposing metal dowels at ends of the vertical stiffening columns.  
     
     
         33 . The method according to  claim 30 , wherein forming the interference fittings comprises providing at least one of stud strips, wall waffles and floor waffles.